Otis Singleton
Electric go-karts are a fun and exciting project for anyone to take on. With the right tools and guidance, you can build your own electric go-kart from scratch, converting an old gas-powered kart or even building one from readily available parts. It is a challenging but rewarding process that can result in a kart that performs better than expected. Whether you're an experienced builder or a novice, there are many resources available to help you get started, including online communities and step-by-step guides. Once you've sourced the necessary parts and assembled your kart, you'll be ready to hit the track and experience the thrill of driving your very own electric go-kart!
| Characteristics | Values |
|---|---|
| Top speed | 50 kph |
| Motor | 4200W |
| Battery | 60V 80Ah |
| Drive time | 20-30 minutes |
| Sprocket ratio | 3:1 |
| Rear sprocket | 64 tooth |
| Drive sprocket | 23 tooth |
| Chain type | #35 |
| Motor mount | L-bracket |
| Weight | As light as possible |
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What You'll Learn
Converting a gas-powered go-kart to electric
Sourcing a Go-Kart
The first step is to source a suitable go-kart. You can either purchase a new or used go-kart, or you may choose to build one yourself. When purchasing a used go-kart, ensure that parts such as the floor, wheels, tires, and seat are in good condition to save on rebuilding costs.
Electric Go-Kart Conversion Kits
Conversion kits typically include all the essential components for the project, such as an electric motor, controller, battery packs, wiring, and other accessories. It is important to select a kit that is compatible with your go-kart's frame and size.
Installation Process
The installation process will vary depending on the specific kit and go-kart being used. However, some general steps may include:
- Removing the gas engine and associated components
- Installing the electric motor and mounting plate: Ensure the motor is positioned correctly, with the drive wheel mounted on the appropriate side of the go-kart, depending on its direction of rotation.
- Connecting the battery packs and charging system: Consider using multiple chargers for consistent charging and easier transportation.
- Mounting the wheels and tires: Use spacers to ensure the tires are positioned at a safe distance from the frame.
- Installing the throttle and speed control: You may choose to use a metal "gas" pedal or an electronic foot control throttle.
Testing and Adjustments
Once the initial installation is complete, it is important to test the go-kart and make any necessary adjustments. Pay attention to factors such as steering, weight distribution, and battery placement to ensure optimal performance and handling.
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Sourcing parts
Engine and Electrical Components:
Electric go-kart motors vary in size, power, voltage, speed, and design. When sourcing a motor, consider the desired speed and power output. Websites like Hyperpowersports.com offer electric scooter parts, including motors, speed controllers, and batteries. You can also find similar parts on Aliexpress and eBay. If you're on a budget, consider a second-hand motor, but ensure it is in good working condition.
Batteries and Battery Charger:
Lithium-ion batteries are ideal for electric go-karts, but they can be expensive. If you're on a budget, lead-acid batteries are a more affordable option, but they may require more maintenance and frequent replacement. Don't forget to source a suitable battery charger as well.
Throttle and Controller:
You can choose between a hand throttle or a foot throttle for your go-kart. Cable pull throttles are available on eBay and Amazon.de for less than $20. For the controller, consider the Kelly KDZ48300, which can be purchased from kellycontroller.com. This controller includes J1 and J2 cables for connecting the throttle, lights, and other components.
Brakes and Sprockets:
A simple disc brake connected to a foot pedal at the front of the go-kart is a common choice. For the sprockets, consider the number of teeth and their ratio to adjust the rear ratio of the go-kart. A typical combination is a 12-tooth sprocket on the motor and a 61-tooth sprocket on the axle.
Body and Frame:
You can source a pre-built go-kart body and frame or build your own. If you're starting with a rusty or old go-kart frame, ensure you strip it down, remove rust, and repaint it. Consider using oil-based paint like Rustoleum for a durable finish. Don't forget to check that the frame size is comfortable for your height.
Additional Parts:
Depending on your specific go-kart design and features, you may need additional parts such as lights (LED or halogen), an air filter to keep the engine air clean, and a radiator for cooling if your go-kart has a high-performance engine.
Remember to create a detailed list of the parts you need, compare prices from different suppliers, and always prioritize quality and safety when sourcing parts for your electric go-kart.
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Assembling the kart
Building an electric go-kart is an exciting project, but it requires careful planning and a good understanding of the various components involved. Here is a step-by-step guide to assembling an electric go-kart:
Planning and Materials:
Begin by deciding on the purpose of your go-kart. Do you want an off-road vehicle or one with a reverse gear? These decisions will impact your design and the parts you need. Set a budget and determine your desired speed and performance. Research and make a list of all the necessary parts, including the motor, battery, and wheels. You can source these parts online, from specialist retailers, or even salvage some from scrap yards or old machines.
Chassis and Frame:
The chassis is the foundation of your go-kart, so ensure it is sturdy and suits your needs. You can either build it from scratch by welding together metal pieces or purchase a pre-made chassis, sometimes called "Pillar Bearing Units." If you're building it yourself, ensure the welds are of adequate depth and uniformity to avoid a brittle or weak structure. Clean the frame of any corrosion, especially if you're converting a gas-powered kart to electric.
Seat Assembly:
The seat should be comfortable and secure. You can build a seat from plywood, bolting it to the frame and covering it with high-density foam and marine vinyl for comfort and durability. Alternatively, you may be able to salvage a suitable seat from an old go-kart or car at a junkyard. Ensure the seat leaves enough room for the steering, engine, and other controls.
Motor, Battery, and Controller:
The motor, battery, and controller are the heart of your electric go-kart. Decide on the type of motor (brushed or brushless) and battery (lithium or lead-acid) based on your budget and performance needs. The controller regulates the current sent to the motor based on throttle input, so ensure it is compatible with your motor and battery. Connect all the electrical components, including the speed controller, to the battery.
Steering and Brakes:
Use steel rods for your steering linkages and axles, bending them to the required angles. Ensure adjustable links are provided for proper steering alignment. Install small racing wheels for better acceleration and control, and don't forget to add brakes for safety. A simple disc brake connected to a foot pedal at the front is a common choice for go-karts.
Assembling an electric go-kart requires time, patience, and a good understanding of the mechanical and electrical systems involved. Always refer to detailed guides and videos specific to your go-kart model for a safe and successful build.
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Testing and safety checks
Helmet and Neck Protection
Wear a helmet to protect your head from obstacles and reduce the impact of accidents, minimising potential head injuries. It is also important to protect your neck, as it provides stability to your head and body, which is critical when racing.
Course Familiarisation
Familiarise yourself with the course before driving. Even if you have driven on the same course before, it is important to check for any changes or potential new hazards. This will enable you to be prepared and evade any dangers.
Equipment Maintenance
Ensure that the main components of the go-kart are in good condition. Faulty equipment, such as brakes, worn-out tyres, faulty steering wheels, faulty gas tanks, and loose gas caps, can lead to accidents. Regularly check your go-kart's tyre pressure and look for any signs of wear or damage on the tyres. Inspect the brakes before each use to ensure they are functioning effectively.
Visibility and Communication
Your go-kart should be equipped with proper lighting, including headlights, taillights, and reflectors, to ensure visibility for yourself and other drivers. Mirrors are also essential, providing a clear view of your surroundings. Turn signals and a horn facilitate communication with other drivers, helping to prevent accidents.
Tyre Selection
Choose the right tyres for your go-kart based on the track conditions. Slicks are ideal for dry, paved tracks, while wet tyres are designed for damp conditions. Treaded tyres offer a balance for varied conditions. Select reputable brands and ensure proper sizing and compound selection for optimal performance and safety.
Chain, Battery, and Frame Inspection
Examine the chain to ensure it is well-lubricated and properly tensioned. Verify that the battery is adequately charged, and inspect the frame for any cracks or damage that may affect stability.
Legal Compliance
If you plan to drive your go-kart on public roads, ensure that it meets legal requirements. This includes having essential instruments such as headlights, tail lights, turn signals, a horn, and a speedometer. Your go-kart must also have a reliable seatbelt system, rear-view mirrors, and a windshield with functional wipers. It should pass the annual MOT test, assessing safety features, roadworthiness, and exhaust emissions.
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Driving and maintenance
Driving an electric go-kart is similar to driving a traditional go-kart. However, there are some key differences to be aware of. Firstly, electric go-karts are typically quieter and lighter than their gas-powered counterparts, making them suitable for indoor use. This can be beneficial when it comes to finding a suitable driving location.
When driving an electric go-kart, it is important to be mindful of the battery life and motor temperature. To ensure optimal performance and prolong battery life, it is recommended to drive the go-kart for shorter periods, allowing the motor to cool off between uses. Keeping the weight of the go-kart as light as possible will also enhance its performance.
Maintenance of an electric go-kart primarily involves taking care of the electrical components. It is crucial to ensure that all wiring is securely fastened to the frame, using zip ties or locks/hooks, to minimise the risk of electrical shorts, which could damage the go-kart. Regularly checking the chain tension and ensuring proper alignment of the rear and drive sprockets are also important maintenance tasks.
Additionally, it is beneficial to inspect the go-kart thoroughly before each use, paying close attention to the condition of the frame, tyres, and other mechanical parts. This includes checking for any loose bolts or potential issues with the steering and braking systems. By conducting regular maintenance and inspections, you can help ensure the safety and optimal performance of your electric go-kart.
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Frequently asked questions
A motor, a battery, and some wheels.
A 4200W motor with a 60V 80Ah battery should be able to run for 20-30 minutes at 25-30 mph.
Three wheels are ideal for an electric go-kart as it saves money and is more efficient.
It is recommended to drive an electric go-kart for only about 20 minutes at a time to allow the motor to cool off.
It is important to ensure that the wiring is securely strapped to the frame and that there are no possibilities for a short circuit.
